Baling Refining Department Problem Solving Platform Helps Styrene Unit Increase Production and Increase Efficiency

- Apr 03, 2019-

In late March, the styrene plant of the Baling Petrochemical Refining Department once again organized a continuous improvement of the value stream map analysis, combing the bottlenecks in the operation and energy saving of the device, and proposing optimization and improvement measures. This is the normal state that the device adheres to the problem-oriented, solves the problem through the problem-solving platform, and taps the potential.

Solve problems online and promote long-term operation of the device. The styrene plant has an annual production capacity of 120,000 tons, which is mainly used to supply raw materials for downstream chemical plants. The ethylbenzene evaporation heat exchanger of the device has experienced internal leakage, which causes ethylbenzene to leak into the steam condensate. If it is stopped, it will directly affect the output of nearly 7,500 tons in 20 days, and increase the consumption of open and stop materials and energy consumption. Ten thousand yuan. In this regard, the styrene plant combines the characteristics of the process, proposes the transformation method and is recognized by the design unit. The steam condensate is used as the system water, and the ethylbenzene vapor separation tank is introduced, which solves the problem quickly and ensures the continuous operation of the device.

Implement “minimally invasive surgery” to stabilize product quality. Li Qin, director of the device, said that in the middle of last year, the polymer content of styrene products was continuously high, fluctuating within the range of 6-9 mg/kg. Although it can meet the national standard requirements, it is less than 3 mg/kg expected by users. There are still gaps in the goals. Therefore, the device immediately organized the research, and held five “brainstorming sessions” to formulate action plans for six major projects and 35 small projects, and implemented optimized “minimally invasive surgery” on the styrene separation tower to stabilize the polymer content. Below 3 mg / kg, it is welcomed by customers.

Reduce energy consumption by using big data. Since the fourth quarter of last year, due to the failure of the system heat exchanger, the separation tower of the styrene plant has intermittent evacuation, and the operation fluctuates greatly, increasing the amount of steam. The equipment set up a research team, using a real-time database to compare more than 4,000 data of 20 important parameters, analyzing and testing more than 50 batches, and concluded that "heat exchanger failure caused the material to bring water to cause fluctuations in operation". They decisively implemented the process transformation. After the water was cut out of the system, the hourly steam consumption was reduced by about 1 ton, and the monthly energy consumption was reduced by nearly 100,000 yuan.

Li Qin said that since 2015, the styrene plant has routinely discovered and solved the problem of the device, insisted on “general problems, and complicated problems, and worked hard to solve problems”, and continued to promote energy conservation, consumption reduction and production increase. Economic and technical indicators such as output, production, material consumption and energy consumption continue to record, producing more than 480,000 tons of styrene, which has remained profitable for years.